US20090242613A1 - Method and apparatus of friction welding - Google Patents
Method and apparatus of friction welding Download PDFInfo
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- US20090242613A1 US20090242613A1 US12/415,192 US41519209A US2009242613A1 US 20090242613 A1 US20090242613 A1 US 20090242613A1 US 41519209 A US41519209 A US 41519209A US 2009242613 A1 US2009242613 A1 US 2009242613A1
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- workpiece
- friction welding
- high frequency
- workpieces
- friction
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Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K20/00—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating
- B23K20/12—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating the heat being generated by friction; Friction welding
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K20/00—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating
- B23K20/12—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating the heat being generated by friction; Friction welding
- B23K20/1205—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating the heat being generated by friction; Friction welding using translation movement
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21C—MANUFACTURE OF METAL SHEETS, WIRE, RODS, TUBES OR PROFILES, OTHERWISE THAN BY ROLLING; AUXILIARY OPERATIONS USED IN CONNECTION WITH METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL
- B21C23/00—Extruding metal; Impact extrusion
- B21C23/02—Making uncoated products
- B21C23/04—Making uncoated products by direct extrusion
- B21C23/08—Making wire, bars, tubes
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K13/00—Welding by high-frequency current heating
- B23K13/01—Welding by high-frequency current heating by induction heating
- B23K13/015—Butt welding
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- C—CHEMISTRY; METALLURGY
- C21—METALLURGY OF IRON
- C21D—MODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS; GENERAL DEVICES FOR HEAT TREATMENT OF FERROUS OR NON-FERROUS METALS OR ALLOYS; MAKING METAL MALLEABLE, e.g. BY DECARBURISATION OR TEMPERING
- C21D1/00—General methods or devices for heat treatment, e.g. annealing, hardening, quenching or tempering
- C21D1/34—Methods of heating
- C21D1/42—Induction heating
Definitions
- the present invention relates to a method and an apparatus of friction welding a pair of workpieces together by pressing one of the workpieces against the other workpiece while rotating the workpieces relatively.
- Japanese Unexamined Patent Application Publication No. 6-248350 discloses welding a pair of pipes together by other than the friction welding. In this publication, however, a pipe joined by welding a pair of pipes is heat-treated at a position adjacent to a joint of the pipe by high frequency induction heating.
- the present invention is directed to a method and an apparatus of friction welding wherein the joined workpiece is increased in tensile strength and improved in appearance.
- a friction welding method includes a step of friction welding a first workpiece and a second workpiece together by pressing the first workpiece against the second workpiece relatively while rotating the two workpieces relatively, and a step of annealing the friction welded workpiece at a position adjacent to a welded portion thereof with high frequency induction heating.
- a friction welding apparatus for friction welding a first workpiece and a second workpiece together by pressing the first workpiece against the second workpiece relatively while rotating the two workpieces relatively.
- the friction welding apparatus includes a high frequency induction heater for annealing the friction welded workpiece at a position adjacent to a welded portion thereof with high frequency induction heating.
- FIG. 1 is a front view showing a friction welding apparatus
- FIG. 2 is a fragmentary view taken in the direction of the arrows along the line II-II of FIG. 1 ;
- FIG. 3 is a flow chart showing a friction welding method
- FIG. 4 is a front view showing a friction welded workpiece
- FIG. 5 is a cross sectional view taken in the direction of the arrows along the line V-V of FIG. 4 ;
- FIG. 6 is a front view showing a first workpiece and a second workpiece to be friction welded
- FIG. 7 is a graph showing a relationship between time and temperature in a step of high frequency induction heating.
- FIG. 8 is a view showing a relationship between time and controllable factors in a step of friction welding.
- the friction welding apparatus 1 includes a bed 8 , a first holder 2 (spindle unit) and a second holder 3 .
- a guide 6 is mounted on the bed 8 at a position adjacent to the left end thereof.
- the first holder 2 is mounted movably relative to the guide 6 and moved along the guide 6 by thrust motor (not shown).
- the second holder 3 is mounted immovably on the bed 8 at the right end thereof.
- the first holder 2 has a chuck 2 A for removably holding a first workpiece W 1 in the form of a round bar.
- a motor 4 is mounted on the first holder 2 and operable to rotate the chuck 2 A on the axis thereof.
- the second holder 3 has a chuck 3 A for removably holding a second workpiece W 2 in the form of a round bar.
- a motor 5 is mounted on the second holder 3 and operable to rotate the chuck 3 A on the axis thereof.
- a high frequency induction heater 7 is mounted on the first holder 2 for induction heating a workpiece W. It is noted that the workpiece W is formed by friction welding the first workpiece W 1 and the second workpiece W 2 together.
- the high frequency induction heater 7 includes a coil 7 A and a moving mechanism 7 B.
- the moving mechanism 7 B has a stationary part 7 B 1 mounted on the first holder 2 and a movable part 7 B 2 mounted so as to be vertically movable relative to the stationary part 7 B 1 .
- the coil 7 A is mounted on the movable part 7 B 2 at the lower end thereof. As shown in FIG. 2 , the coil 7 A is horseshoe-shaped and has an opening 7 A 1 that is opened downwardly. Therefore, when the coil 7 A is moved toward the workpiece W by the moving mechanism 7 B, the workpiece W is positioned into the opening 7 A 1 , and the coil 7 A surrounds a part of the outer periphery of the workpiece W.
- FIG. 3 shows a state where the workpiece W is removed from the chuck 3 A after the step of friction welding. Then, the first workpiece WI is rotated on its axis with the chuck 2 A by the motor 4 while the second workpiece W 2 is held with the chuck 3 A so as not to be rotated on its axis.
- the first holder 2 is moved toward the second holder 3 thereby to bring the first workpiece W 1 into contact with the second workpiece W 2 .
- frictional heat is generated between the first and second workpieces W 1 and W 2 thereby to frictionally weld the first and second workpieces W 1 and W 2 together.
- operation of the motor 4 is controlled by controller (not shown) thereby to rotate the first workpiece W 1 at a rotational speed A 1 ranging from 3300 to 10000 rpm, for example. If the rotational speed A 1 is excessively low, seizure may occur at the outer peripheries of the first and second workpieces W 1 and W 2 . Immediately after the occurrence of seizure, the two workpieces W 1 and W 2 may be ruptured due to torsion caused by relative rotation therebetween. In this case, there is possibility that heat generated by the rupture is rapidly increased and burr is formed.
- operation of the thrust motor is controlled to provide the first holder 2 with an axial pressure P 0 thereby to move the first workpiece W 1 toward the second workpiece W 2 .
- operation of the thrust motor is controlled to provide the first holder 2 with an axial pressure P 1 .
- the first holder 2 is movably held in the direction away from the second holder 3 without moving toward the second holder 3 from the position where the first and second workpieces W 1 and W 2 are in contact with each other (refer to the period of time T 1 of FIG. 8 , which is a friction step).
- the axial pressure P 1 is set, for example, in the range of 5 to 10 MPa.
- the friction step has a shortage of frictional heat.
- the friction step is finished before a burn-off length is formed. If the axial pressure P 1 is excessively high, such a burn-off length is rapidly formed in the friction step thereby to form an excessive amount of burr.
- the period of time T 1 may be predetermined. If the two workpieces W 1 and W 2 are made of steel, the period of time T 1 is set in the range of 0.05 second to 1 second.
- the upset pressure P 2 is preferably set larger than the axial pressure P 1 in the friction step by a factor of two to four times.
- the upset pressure P 2 is set, for example, in the range of 10 through 30 MPa
- the second workpiece W 2 starts to freely run with the first workpiece W 1 so that the two workpieces W 1 and W 2 rotate at the same speed after a lapse of time T 1 and T 2 (refer to the period of time T 2 of FIG. 8 , which is an upset step). Then, the two workpieces W 1 and W 2 are stopped rotating (refer to the period of time T 3 of FIG. 8 , which is also an upset process). Both of the time T 2 and T 3 are set, for example, in the range of 0.5 to 1 second. For a period of time T 4 around the time when the relative rotation between the two workpieces W 1 and W 2 is zero, an upset length B is formed between the two workpieces W 1 and W 2 .
- the upset length B is formed, for example, in the range of 0.05 to 0.2 mm.
- the step of anneal treatment is performed as shown in FIG. 3 .
- the workpiece W is removed from the chuck 3 A as shown in FIG. 1 .
- the coil 7 A is moved close to a welded portion W 3 of the workpiece W and high frequency current is flowed through the coil 7 A.
- operation of the motor 4 is controlled to rotate the workpiece W on its axis.
- high frequency induction heating is generated in the entirety of the outer periphery of the workpiece W adjacent to the welded portion W 3 .
- the high frequency induction heating is preferably initiated before the frictional heat generated in the step of friction welding is cooled completely. Thus, a necessary energy for high frequency induction heating is reduced.
- the high frequency current flowed through the coil 7 A is controlled to keep the outermost peripheral surface of the welded portion W 3 at a predetermined temperature ranging from Temp 1 to Temp 1 + ⁇ as shown in FIG. 7 .
- the high frequency current is, for example, on-off controlled so that the value of Temp 1 ranges from 300° C. to 600° C. and the value of ⁇ is 50° C.
- the frequency of the current is set, for example, in the range of 5 to 120 kHz.
- the retention time t 1 of the predetermined temperature is set, for example, in the range of 1 to 15 seconds. After high frequency induction heating is generated, the workpiece W is left as it is and slowly cooled.
- the two workpieces W 1 and W 2 are made of steel, including high carbon steel such as S55C and mild steel such as S15C.
- the two workpieces W 1 and W 2 are in the shape of solid or hollow rod or round bar.
- the two workpieces W 1 and W 2 are formed by extrusion molding as shown in FIG. 6 , so that both workpieces W 1 and W 2 have fiber flows W 5 and W 6 (flow of metal structure) that extend axially, respectively.
- the welded portion W 3 of the workpiece W has a fiber flow W 7 (flow of metal structure) that extends radially and circumferentially as shown in FIGS. 4 and 5 .
- the high frequency induction heating has a property in which induction current tends to flow along a fiber flow.
- high frequency induction heating tends to be generated at a position adjacent to the welded portion W 3 along the fiber flow W 7 in the radial direction of the workpiece W rather than in the axial direction thereof.
- the anneal treatment was actually tested and its effect was confirmed.
- the round bar made of S55C is friction welded by a method of low heat input to prepare eight specimens Nos 1 to 8. Then, temperature of the outermost peripheral surface of the welded portion W 3 of each specimen was controlled using a frequency for a period of retention time as shown in Table 1.
- the step includes a process of heating up for 5 seconds, a process of retaining a target temperature and a process of cooling.
- the workpiece which had not undergone the step of anneal treatment and the workpiece which had undergone the step of anneal treatment were tested in tensile strength.
- the workpiece which had not undergone the step of anneal treatment was ruptured at the heat-affected zone under a pressure of 756 MPa.
- the workpiece which had undergone the step of anneal treatment was ruptured at the base portion rather than at the heat-affected zone and Rts tensile strength was also increased.
- the tensile strengths of the specimens Nos. 6 and 7 were 782 MPa and 773 MPa, respectively. Even when the outermost peripheral surface was kept at 300° C. for 10 seconds as in the case of the specimen No.
- the friction welding method includes the step of friction welding and the step of anneal treatment which performs anneal treatment by high frequency induction heating. Therefore, the workpiece W has an increased tensile strength by high frequency induction heating.
- the reason for the increased tensile strength is presumed as follows after deliberate consideration. Due to friction welding, microscopic region of which hardness is distinctly changed is developed adjacent to the outer peripheral portion of the welded portion W 3 and it becomes an origin of rupturing in testing tensile strength. However, the microscopic region of which hardness is distinctly changed is gradated by anneal treatment of high frequency induction heating, so that the workpiece W is increased in tensile strength.
- Anneal treatment according to the present embodiment is not conventionally performed and effectively applied to the workpiece W. More specifically, friction welding the first and second workpieces W 1 and W 2 together, the friction welded workpiece W has the fiber flow W 7 that extends radially, which is not formed by other welding process. Because induction current tends to flow along such a fiber flow, high frequency induction heating tends to be generated at a position adjacent to the welded portion W 3 along the fiber flow W 7 in the radial direction of the workpiece W rather than in the axial direction thereof. Therefore, the microscopic region of which hardness is distinctly changed adjacent to the welded portion W 3 is gradated efficiently by high frequency induction heating. The high frequency induction heating reduces an oxidized region of the workpiece W compared to the conventional electric furnace. Thus, annealed workpiece W is improved in appearance.
- the first and second workpieces W 1 and W 2 are in the form of a bar and have fiber flows W 5 and W 6 that extends axially.
- the fiber flow W 7 extending radially is formed in the welded portion W 3 of the workpiece W by pressing the first and second workpieces W 1 and W 2 against each other while rotating the two workpieces W 1 and W 2 on the axis thereof relatively. Therefore, the high frequency induction heating tends to be generated at a position adjacent to the welded portion W 3 along the fiber flows W 5 , W 6 and W 7 . Thus, the tensile strength of the workpiece W is effectively increased.
- the high frequency induction heating is executed so as to keep the outermost peripheral surface of the welded portion W 3 at a temperature of 300 to 650° C. for 1 to 15 seconds. Therefore, the high frequency induction heating has lower preset temperature and shorter treating time than the conventional electric.
- the step of friction welding preferably includes a friction step (T 1 ) and an upset step (T 2 , T 3 ) as shown in FIG. 8 .
- T 1 a friction step
- T 2 , T 3 an upset step
- the total upset length in the step of friction welding is reduced thereby to reduce burr formation.
- the time to perform the step of friction welding is extremely shortened. Because the heat generated is reduced and the workpiece W tends to be rapidly cooled, on the other hand, there is possibility that microscopic region of which hardness is distinctly changed may be developed adjacent to the outer peripheral surface of the welded portion W 3 . However, such a region is gradated by high frequency induction heating. Therefore, the tensile strength of the workpiece W is positively increased. Because the step of friction welding shown in FIG. 8 has less burr formation, high frequency induction heating is effectively applicable to the workpiece W even before burr is eliminated.
- the friction welding apparatus 1 is provided with the high frequency induction heater 7 as shown in FIG. 1 . Therefore, the motion welding apparatus 1 is made compact compared to the prior system where a friction welding apparatus and an electric furnace are separately provided.
- the high frequency induction heater 7 has the coil 7 A that is allowed to be disposed at a position adjacent to a part of the outer peripheral surface of the welded portion W 3 of the workpiece W as shown in FIGS. 1 and 2 .
- High frequency induction heating is generated In the entirety of the outer periphery of the welded portion W 3 by flowing high frequency current through the coil 7 A while rotating the workpiece W. Therefore, it is not necessary for the coil to surround the entire of the outer periphery of the workpiece W. This facilitates the operation of the heat treatment
- the friction welding apparatus 1 includes the motor 4 for rotating the first and second workpieces W 1 and W 2 relatively, the motor 4 is used for rotating the workpiece W while high frequency current is flowed through the coil 7 A.
- the present invention is not limited to the above-described embodiment, but it may be modified as exemplified below.
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Abstract
A friction welding method includes a step of friction welding a first workpiece and a second workpiece together by pressing the first workpiece against the second workpiece relatively while rotating the two workpieces relatively, and a step of annealing the friction welded workpiece at a position adjacent to a welded portion thereof with high frequency induction heating.
Description
- The present invention relates to a method and an apparatus of friction welding a pair of workpieces together by pressing one of the workpieces against the other workpiece while rotating the workpieces relatively.
- When a workpiece joined by friction welding a pair of workpieces together is tested in tensile strength, the joined workpiece is ruptured generally in its heat-affected zone adjacent to a joint of the workpiece. When the joined workpiece is annealed, the heat-affected zone of the annealed workpiece is strengthened. Thus, when the annealed workpiece is tested in tensile strength, the annealed workpiece is ruptured in its base portion. On the other hand, Japanese Unexamined Patent Application Publication No. 6-248350 discloses welding a pair of pipes together by other than the friction welding. In this publication, however, a pipe joined by welding a pair of pipes is heat-treated at a position adjacent to a joint of the pipe by high frequency induction heating.
- It is common to use an electric furnace in annealing the joined workpiece. When the electric furnace anneals the joined workpiece made of carbon steel of S55C with a diameter of 12 mm, for example, it takes about two hours under a temperature of 650° C. In this case, the outer surface of the joined workpiece is oxidized and looks ugly. In view of the problems, the present invention is directed to a method and an apparatus of friction welding wherein the joined workpiece is increased in tensile strength and improved in appearance.
- In accordance with an aspect of the present invention, a friction welding method includes a step of friction welding a first workpiece and a second workpiece together by pressing the first workpiece against the second workpiece relatively while rotating the two workpieces relatively, and a step of annealing the friction welded workpiece at a position adjacent to a welded portion thereof with high frequency induction heating.
- In accordance with another aspect of the present invention, there is provided a friction welding apparatus for friction welding a first workpiece and a second workpiece together by pressing the first workpiece against the second workpiece relatively while rotating the two workpieces relatively. The friction welding apparatus includes a high frequency induction heater for annealing the friction welded workpiece at a position adjacent to a welded portion thereof with high frequency induction heating.
- Other aspects and advantages of the invention will become apparent from the following description, taken in conjunction with the accompanying drawings, illustrating by way of example the principles of the invention.
- The features of the present invention that are believed to be novel are set forth with particularity in the appended claims. The invention together with objects and advantages thereof, may best be understood by reference to the following description of the presently preferred embodiments together with the accompanying drawings in which:
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FIG. 1 is a front view showing a friction welding apparatus; -
FIG. 2 is a fragmentary view taken in the direction of the arrows along the line II-II ofFIG. 1 ; -
FIG. 3 is a flow chart showing a friction welding method; -
FIG. 4 is a front view showing a friction welded workpiece; -
FIG. 5 is a cross sectional view taken in the direction of the arrows along the line V-V ofFIG. 4 ; -
FIG. 6 is a front view showing a first workpiece and a second workpiece to be friction welded; -
FIG. 7 is a graph showing a relationship between time and temperature in a step of high frequency induction heating; and -
FIG. 8 is a view showing a relationship between time and controllable factors in a step of friction welding. - The following will describe an embodiment of the present invention with reference to
FIGS. 1 through 8 . Referring toFIG. 1 , thefriction welding apparatus 1 includes abed 8, a first holder 2 (spindle unit) and asecond holder 3. Aguide 6 is mounted on thebed 8 at a position adjacent to the left end thereof. Thefirst holder 2 is mounted movably relative to theguide 6 and moved along theguide 6 by thrust motor (not shown). Thesecond holder 3 is mounted immovably on thebed 8 at the right end thereof. Thefirst holder 2 has achuck 2A for removably holding a first workpiece W1 in the form of a round bar. Amotor 4 is mounted on thefirst holder 2 and operable to rotate thechuck 2A on the axis thereof. Likewise, thesecond holder 3 has achuck 3A for removably holding a second workpiece W2 in the form of a round bar. Amotor 5 is mounted on thesecond holder 3 and operable to rotate thechuck 3A on the axis thereof. - A high
frequency induction heater 7 is mounted on thefirst holder 2 for induction heating a workpiece W. It is noted that the workpiece W is formed by friction welding the first workpiece W1 and the second workpiece W2 together. The highfrequency induction heater 7 includes acoil 7A and amoving mechanism 7B. Themoving mechanism 7B has a stationary part 7B1 mounted on thefirst holder 2 and a movable part 7B2 mounted so as to be vertically movable relative to the stationary part 7B1. Thecoil 7A is mounted on the movable part 7B2 at the lower end thereof. As shown inFIG. 2 , thecoil 7A is horseshoe-shaped and has an opening 7A1 that is opened downwardly. Therefore, when thecoil 7A is moved toward the workpiece W by themoving mechanism 7B, the workpiece W is positioned into the opening 7A1, and thecoil 7A surrounds a part of the outer periphery of the workpiece W. - To join the first workpiece W1 and the second workpiece W2 together by the
friction welding apparatus 1 the step of friction welding is first performed and the step of anneal treatment is then performed as shown inFIG. 3 . In the step of friction welding, to begin with, the first and second workpieces W1 and W2 are held by thechucks FIG. 1 shows a state where the workpiece W is removed from thechuck 3A after the step of friction welding. Then, the first workpiece WI is rotated on its axis with thechuck 2A by themotor 4 while the second workpiece W2 is held with thechuck 3A so as not to be rotated on its axis. Subsequently, thefirst holder 2 is moved toward thesecond holder 3 thereby to bring the first workpiece W1 into contact with the second workpiece W2. Thus, frictional heat is generated between the first and second workpieces W1 and W2 thereby to frictionally weld the first and second workpieces W1 and W2 together. - Referring to
FIG. 8 , operation of themotor 4 is controlled by controller (not shown) thereby to rotate the first workpiece W1 at a rotational speed A1 ranging from 3300 to 10000 rpm, for example. If the rotational speed A1 is excessively low, seizure may occur at the outer peripheries of the first and second workpieces W1 and W2. Immediately after the occurrence of seizure, the two workpieces W1 and W2 may be ruptured due to torsion caused by relative rotation therebetween. In this case, there is possibility that heat generated by the rupture is rapidly increased and burr is formed. - Then, operation of the thrust motor is controlled to provide the
first holder 2 with an axial pressure P0 thereby to move the first workpiece W1 toward the second workpiece W2. When the first workpiece W1 is brought into contact with the second workpiece W2 to generate frictional heat therebetween, operation of the thrust motor is controlled to provide thefirst holder 2 with an axial pressure P1. In this case, thefirst holder 2 is movably held in the direction away from thesecond holder 3 without moving toward thesecond holder 3 from the position where the first and second workpieces W1 and W2 are in contact with each other (refer to the period of time T1 ofFIG. 8 , which is a friction step). The axial pressure P1 is set, for example, in the range of 5 to 10 MPa. If the axial pressure P1 is excessively low, the friction step has a shortage of frictional heat. In the present embodiment, the friction step is finished before a burn-off length is formed. If the axial pressure P1 is excessively high, such a burn-off length is rapidly formed in the friction step thereby to form an excessive amount of burr. Providing a low axial pressure P1 and a high rotational speed A1 as described above, it is possible that the joint surfaces between the two workpieces W1 and W2 are heated in the friction step without forming such a burn-off length. The period of time T1 may be predetermined. If the two workpieces W1 and W2 are made of steel, the period of time T1 is set in the range of 0.05 second to 1 second. - After the friction step is finished, restricting the rotation of the first workpiece W1 is initiated. Then, operation of the thrust motor is controlled to provide an upset pressure P2 between the two workpieces W1 and W2. The upset pressure P2 is preferably set larger than the axial pressure P1 in the friction step by a factor of two to four times. The upset pressure P2 is set, for example, in the range of 10 through 30 MPa When restricting the rotation of the first workpiece W1 is initiated, operation of the
motor 5 is controlled to allow thechuck 3A to be rotatable on its axis. Thus, the second workpiece W2 starts to freely run with the first workpiece W1 so that the two workpieces W1 and W2 rotate at the same speed after a lapse of time T1 and T2 (refer to the period of time T2 ofFIG. 8 , which is an upset step). Then, the two workpieces W1 and W2 are stopped rotating (refer to the period of time T3 ofFIG. 8 , which is also an upset process). Both of the time T2 and T3 are set, for example, in the range of 0.5 to 1 second. For a period of time T4 around the time when the relative rotation between the two workpieces W1 and W2 is zero, an upset length B is formed between the two workpieces W1 and W2. The upset length B is formed, for example, in the range of 0.05 to 0.2 mm. - After the step of friction welding, the step of anneal treatment is performed as shown in
FIG. 3 . In the step of anneal treatment, to begin with, the workpiece W is removed from thechuck 3A as shown inFIG. 1 . Then, thecoil 7A is moved close to a welded portion W3 of the workpiece W and high frequency current is flowed through thecoil 7A. Then, operation of themotor 4 is controlled to rotate the workpiece W on its axis. Thus, high frequency induction heating is generated in the entirety of the outer periphery of the workpiece W adjacent to the welded portion W3. The high frequency induction heating is preferably initiated before the frictional heat generated in the step of friction welding is cooled completely. Thus, a necessary energy for high frequency induction heating is reduced. - The high frequency current flowed through the
coil 7A is controlled to keep the outermost peripheral surface of the welded portion W3 at a predetermined temperature ranging from Temp1 to Temp1+α as shown inFIG. 7 . The high frequency current is, for example, on-off controlled so that the value of Temp1 ranges from 300° C. to 600° C. and the value of α is 50° C. The frequency of the current is set, for example, in the range of 5 to 120 kHz. The retention time t1 of the predetermined temperature is set, for example, in the range of 1 to 15 seconds. After high frequency induction heating is generated, the workpiece W is left as it is and slowly cooled. - The two workpieces W1 and W2 are made of steel, including high carbon steel such as S55C and mild steel such as S15C. The two workpieces W1 and W2 are in the shape of solid or hollow rod or round bar. The two workpieces W1 and W2 are formed by extrusion molding as shown in
FIG. 6 , so that both workpieces W1 and W2 have fiber flows W5 and W6 (flow of metal structure) that extend axially, respectively. By friction welding the first and second workpieces W1 and W2 together, the welded portion W3 of the workpiece W has a fiber flow W7 (flow of metal structure) that extends radially and circumferentially as shown inFIGS. 4 and 5 . - While conventional electric furnaces tend to heat the outer surface of the workpiece W, they hardly heat the center of the workpiece W. On the other hand, the high frequency induction heating has a property in which induction current tends to flow along a fiber flow. When the high frequency current is flowed through the
coil 7A adjacent to the welded portion W3 of the workpiece W, therefore, high frequency induction heating tends to be generated at a position adjacent to the welded portion W3 along the fiber flow W7 in the radial direction of the workpiece W rather than in the axial direction thereof. Thus, temperature rises in a heat-affected zone W4 of the workpiece W adjacent to the welded portion W3 that is thermally affected in the step of friction welding, so that anneal treatment tends to be performed in the heat-affected zone W4. It is noted that burr W8 formed in the step of friction welding is eliminated from the workpiece W after or before the step of anneal treatment. - The anneal treatment was actually tested and its effect was confirmed. To begin with, the round bar made of S55C is friction welded by a method of low heat input to prepare eight specimens Nos 1 to 8. Then, temperature of the outermost peripheral surface of the welded portion W3 of each specimen was controlled using a frequency for a period of retention time as shown in Table 1. The step includes a process of heating up for 5 seconds, a process of retaining a target temperature and a process of cooling.
-
TABLE 1 frequency No. diameter (mm) retention time (s) temperature (° C.) (KHz) 1 12 10 300 10 2 12 10 400 10 3 12 10 500 10 4 12 10 600 10 5 12 0 600 10 6 17 10 300 24 7 17 10 400 24 8 17 10 400 144 - Then, the workpiece which had not undergone the step of anneal treatment and the workpiece which had undergone the step of anneal treatment were tested in tensile strength. As a result, the workpiece which had not undergone the step of anneal treatment was ruptured at the heat-affected zone under a pressure of 756 MPa. On the other hand, the workpiece which had undergone the step of anneal treatment was ruptured at the base portion rather than at the heat-affected zone and Rts tensile strength was also increased. For example, the tensile strengths of the specimens Nos. 6 and 7 were 782 MPa and 773 MPa, respectively. Even when the outermost peripheral surface was kept at 300° C. for 10 seconds as in the case of the specimen No. 1, the specimen No. 1 was ruptured at the base portion to be found out that anneal treatment of the welded portion W3 was sufficient. Even when the retention time was zero second as in the case of the specimen No. 5, the specimen No. 5 was ruptured at the base portion to be found out that anneal treatment of the welded portion W3 was sufficient.
- As described above, as shown in
FIG. 3 , the friction welding method includes the step of friction welding and the step of anneal treatment which performs anneal treatment by high frequency induction heating. Therefore, the workpiece W has an increased tensile strength by high frequency induction heating. The reason for the increased tensile strength is presumed as follows after deliberate consideration. Due to friction welding, microscopic region of which hardness is distinctly changed is developed adjacent to the outer peripheral portion of the welded portion W3 and it becomes an origin of rupturing in testing tensile strength. However, the microscopic region of which hardness is distinctly changed is gradated by anneal treatment of high frequency induction heating, so that the workpiece W is increased in tensile strength. - Anneal treatment according to the present embodiment is not conventionally performed and effectively applied to the workpiece W. More specifically, friction welding the first and second workpieces W1 and W2 together, the friction welded workpiece W has the fiber flow W7 that extends radially, which is not formed by other welding process. Because induction current tends to flow along such a fiber flow, high frequency induction heating tends to be generated at a position adjacent to the welded portion W3 along the fiber flow W7 in the radial direction of the workpiece W rather than in the axial direction thereof. Therefore, the microscopic region of which hardness is distinctly changed adjacent to the welded portion W3 is gradated efficiently by high frequency induction heating. The high frequency induction heating reduces an oxidized region of the workpiece W compared to the conventional electric furnace. Thus, annealed workpiece W is improved in appearance.
- As shown in
FIG. 6 , the first and second workpieces W1 and W2 are in the form of a bar and have fiber flows W5 and W6 that extends axially. In the step of friction welding, as shown inFIG. 4 , the fiber flow W7 extending radially is formed in the welded portion W3 of the workpiece W by pressing the first and second workpieces W1 and W2 against each other while rotating the two workpieces W1 and W2 on the axis thereof relatively. Therefore, the high frequency induction heating tends to be generated at a position adjacent to the welded portion W3 along the fiber flows W5, W6 and W7. Thus, the tensile strength of the workpiece W is effectively increased. - In the step of anneal treatment, the high frequency induction heating is executed so as to keep the outermost peripheral surface of the welded portion W3 at a temperature of 300 to 650° C. for 1 to 15 seconds. Therefore, the high frequency induction heating has lower preset temperature and shorter treating time than the conventional electric.
- The step of friction welding preferably includes a friction step (T1) and an upset step (T2, T3) as shown in
FIG. 8 . Because the upset length is not formed in the friction step but is formed only in the upset step, the total upset length in the step of friction welding is reduced thereby to reduce burr formation. In addition, the time to perform the step of friction welding is extremely shortened. Because the heat generated is reduced and the workpiece W tends to be rapidly cooled, on the other hand, there is possibility that microscopic region of which hardness is distinctly changed may be developed adjacent to the outer peripheral surface of the welded portion W3. However, such a region is gradated by high frequency induction heating. Therefore, the tensile strength of the workpiece W is positively increased. Because the step of friction welding shown inFIG. 8 has less burr formation, high frequency induction heating is effectively applicable to the workpiece W even before burr is eliminated. - The
friction welding apparatus 1 is provided with the highfrequency induction heater 7 as shown inFIG. 1 . Therefore, themotion welding apparatus 1 is made compact compared to the prior system where a friction welding apparatus and an electric furnace are separately provided. - The high
frequency induction heater 7 has thecoil 7A that is allowed to be disposed at a position adjacent to a part of the outer peripheral surface of the welded portion W3 of the workpiece W as shown inFIGS. 1 and 2 . High frequency induction heating is generated In the entirety of the outer periphery of the welded portion W3 by flowing high frequency current through thecoil 7A while rotating the workpiece W. Therefore, it is not necessary for the coil to surround the entire of the outer periphery of the workpiece W. This facilitates the operation of the heat treatment Because thefriction welding apparatus 1 includes themotor 4 for rotating the first and second workpieces W1 and W2 relatively, themotor 4 is used for rotating the workpiece W while high frequency current is flowed through thecoil 7A. - The present invention is not limited to the above-described embodiment, but it may be modified as exemplified below.
- (1) Although in the above-described embodiment the
friction welding apparatus 1 is provided with the highfrequency induction heater 7, the high frequency induction heater may be separately provided from the friction welding apparatus. - (2) Although in the above-described embodiment the
coil 7A is horseshoe-shaped, a circular or linear coil may be arranged adjacent to and along a part of the outer peripheral surface of the workpiece W. - (3) In the above-described embodiment, the
motor 4 rotates not only the first workpiece W1 in friction welding but also the welded workpiece W after friction welding. However, themotor 5 may rotate the workpiece W after the welded workpiece W is removed from thechuck 2A. Alternatively, it may be so arranged that one of the two motors is freed and the other is rotated without removing the workpiece W from the chucks. Both of the motors may be rotated at the same speed thereby to rotate the workpiece W. - (4) The step of friction welding is not limited to the step shown in
FIG. 8 , but it may be executed by a method of low heat input or a direct drive friction welding. - Therefore, the present examples and embodiments are to be considered as illustrative and not restrictive, and the invention is not to be limited to the details given herein but may be modified within the scope of the appended claims.
Claims (11)
1. A friction welding method comprising the steps of:
friction welding a first workpiece and a second workpiece together by pressing the first workpiece against the second workpiece relatively while rotating the two workpieces relatively; and
annealing the friction welded workpiece at a position adjacent to a welded portion thereof with high frequency induction heating.
2. The friction welding method according to claim 1 , further comprising the step of preparing each of the first workpiece and the second workpiece in the form of a bar before the step of friction welding, each of the first workpiece and the second workpiece has a fiber flow that extends in an axial direction of the bar, wherein the step of friction welding includes a step of forming a fiber flow that extends in a radial direction of the bar in the welded portion by pressing the first workpiece against the second workpiece relatively while rotating the two workpieces on an axis thereof relatively.
3. The friction welding method according to claim 1 , wherein the first workpiece and the second workpiece are formed by extrusion molding.
4. The friction welding method according to claim 1 , wherein the high frequency induction heating is performed by keeping temperature of an outermost peripheral surface of the welded portion in a range of 300 to 650° C. for 1 to 15 seconds.
5. The friction welding method according to claim 1 , wherein the high frequency induction heating is performed while the friction welded workpiece is rotated.
6. The friction welding method according to claim 1 , wherein the high frequency induction heating is initiated before frictional heat generated in the step of friction welding is cooled.
7. The friction welding method according to claim 1 , wherein the step of friction welding comprises the steps of:
generating frictional heat by pressing the first workpiece against the second workpiece relatively while rotating the two workpieces relatively; and
forming an upset length between the two workpieces by restricting the relative rotation between the two workpieces and providing an upset pressure between the two workpieces before a burn-off length is formed between the two workpieces in the step of friction welding.
8. A friction welding apparatus for friction welding a first workpiece and a second workpiece together by pressing the first workpiece against the second workpiece relatively while rotating the two workpieces relatively, comprising:
a high frequency induction heater for annealing the friction welded workpiece at a position adjacent to a welded portion thereof with high frequency induction heating.
9. The friction welding apparatus according to claim 8 , wherein the high frequency induction heater has a coil that is allowed to be disposed at a position adjacent to a part of an outer periphery of the welded portion, wherein when high frequency current is flowed through the coil while the friction welded workpiece is rotated, the high frequency induction heat is generated in the entirety of the outer periphery of the welded portion.
10. The friction welding apparatus according to claim 9 , wherein the high frequency induction heater has a moving mechanism that moves the coil close to or away from the welded portion.
11. The friction welding apparatus according to claim 9 , wherein the coil is horseshoe-shaped and has an opening into which the friction welded workpiece is positioned.
Priority Applications (1)
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US13/240,961 US20120012232A1 (en) | 2008-04-01 | 2011-09-22 | Method and apparatus of friction welding to increase tensile strength of welded workpiece |
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JP2008094930A JP5243083B2 (en) | 2008-04-01 | 2008-04-01 | Friction welding method |
JPP2008-094930 | 2008-04-01 |
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US13/240,961 Division US20120012232A1 (en) | 2008-04-01 | 2011-09-22 | Method and apparatus of friction welding to increase tensile strength of welded workpiece |
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US20090242613A1 true US20090242613A1 (en) | 2009-10-01 |
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US12/415,192 Abandoned US20090242613A1 (en) | 2008-04-01 | 2009-03-31 | Method and apparatus of friction welding |
US13/240,961 Abandoned US20120012232A1 (en) | 2008-04-01 | 2011-09-22 | Method and apparatus of friction welding to increase tensile strength of welded workpiece |
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US13/240,961 Abandoned US20120012232A1 (en) | 2008-04-01 | 2011-09-22 | Method and apparatus of friction welding to increase tensile strength of welded workpiece |
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US (2) | US20090242613A1 (en) |
JP (1) | JP5243083B2 (en) |
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US10919107B2 (en) * | 2016-07-06 | 2021-02-16 | Thyssenkrupp Presta Ag | Rack and method for producing a rack for a steering gear of a motor vehicle |
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US10596657B2 (en) | 2017-03-30 | 2020-03-24 | Hitachi Power Solutions Co., Ltd. | Friction stir welding apparatus, friction stir welding control device, and friction stir welding method |
US20190337088A1 (en) * | 2018-05-04 | 2019-11-07 | GM Global Technology Operations LLC | Welding method and part made by the welding method |
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US11597032B2 (en) * | 2020-03-17 | 2023-03-07 | Paul Po Cheng | Method and system for modifying metal objects |
CN112756770A (en) * | 2020-12-30 | 2021-05-07 | 天津北特汽车零部件有限公司 | Friction welding process for hollow rod |
Also Published As
Publication number | Publication date |
---|---|
CN101549436A (en) | 2009-10-07 |
JP2009248090A (en) | 2009-10-29 |
KR101049784B1 (en) | 2011-07-19 |
KR20090105829A (en) | 2009-10-07 |
CN101549436B (en) | 2012-07-04 |
US20120012232A1 (en) | 2012-01-19 |
JP5243083B2 (en) | 2013-07-24 |
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